KR20150072553A - Decoration film using natural cork materials and method for manufacturing the same - Google Patents

Abstract

It is an object of the present invention to provide a decoration film using natural cork material which can be manufactured in an open skin type by having a cost competitiveness in comparison with a conventional real wood part, realizing a wood texture on the surface thereof, and a manufacturing method thereof.
Accordingly, the present invention provides a nonwoven fabric comprising a bottom layer, an intermediate layer laminated on the base layer, and an uppermost cork layer laminated on the intermediate layer, wherein the intermediate layer comprises a lower adhesive layer, And an upper adhesive layer laminated on the nonwoven fabric layer. The decorating film is made of a natural cork material.

Description

TECHNICAL FIELD The present invention relates to a decorative film using natural cork material and a method for manufacturing the same,

The present invention relates to a decorative film using a natural cork material having cost competitiveness compared to a conventional real wood part and a manufacturing method thereof.

Generally, the interior of a vehicle is provided with a crash pad positioned at the front of the driver's seat and front passenger seat, a panel surrounding the instrument panel assembled to the crash pad, a central fascia panel (where audio, cup holder, ashtray, etc.) And the like are installed with different materials.

In recent years, in order to obtain a sophisticated appearance and a sense of quality, the interior material using a material using a real wood is used.

In the conventional parts using real wood, the substrate to be coated with wood material is first laid on the base layer, and then the real wood is coated on the base material. Then, the surface is coated / polished by the coating / The surface of the real wood is treated smoothly with the gloss and at the same time a visual quality such as wood grain is expressed.

However, in the case where the above-mentioned conventional real wood part is used for molding an automobile interior material or the like, that is, when a molded part such as an automobile interior material (interior material using real wood) is manufactured by using the above-mentioned conventional real wood part There is a problem that the process is complicated and the manufacturing cost is large.

In addition, conventional real wood parts have difficulties in application other than high-end models due to the cost problem of real wood, and because of the difficulty of forming by itself due to the characteristics of real wood (wood veneer) that breaks easily during processing, The cross-sectional structure of the molded part becomes more complicated (see Fig. 5).

Therefore, it is necessary to substitute existing real wood parts, wood processing technology that is simple in manufacturing process and cost competitive.

DISCLOSURE OF THE INVENTION The present invention has been made to overcome the above-mentioned problems, and it is an object of the present invention to provide a decorative film using a natural cork material having cost competitiveness compared to a conventional real wood part, The purpose is to provide.

In order to attain the above object, the present invention is characterized in that it comprises a base layer of the lowest layer, an intermediate layer laminated on the base layer, and an uppermost cork layer laminated on the intermediate layer, wherein the intermediate layer comprises a lower adhesive layer, A nonwoven fabric layer laminated on the nonwoven fabric layer, and an upper adhesive layer laminated on the nonwoven fabric layer.

Preferably, in the embodiment of the present invention, the nonwoven fabric layer is made of a long fiber nonwoven fabric having a density of 10 g / m 2 to 100 g / m 2.

Also preferably, in an embodiment of the present invention, the nonwoven fabric layer is formed using a nonwoven material that is colored with a color similar to or the same as that of the cork layer material.

In the embodiment of the present invention, as the adhesive material for the upper and lower adhesive layers, a material having a melting temperature of 80 to 200 DEG C is used. Of these materials, urethane, acrylic, ester, amide and TPU (thermoplastic polyurethane) , And EVA (ethylene vinyl acetate), or two or more of them are used simultaneously.

For example, a urethane system may be used for the upper adhesive layer and an acrylic system may be used for the lower adhesive layer.

In the embodiment of the present invention, a material for the base layer may be a mixture of ABS (acrylonitrile-butadiene-styrene), PC (polycarbonate) and ABS (acrylonitrile- butadiene- styrene), PET (polyethylene terephthalate) Polypropylene), PC (polycarbonate), and PMMA (polymethyl methacrylate).

Further, in the embodiment of the present invention, it is preferable that the substrate layer is made of a material that is colored with a color similar to or the same as that of the cork layer material.

In an embodiment of the present invention, the cork layer is formed of a cork wood skin layer which is a soft component of cork wood.

According to another aspect of the present invention, there is provided a method for preparing a cork material, comprising the steps of: preparing a substrate layer material, an intermediate layer material, and a cork layer material; And a second step of laminating and co-extruding the above-mentioned materials simultaneously, followed by cold pressing immediately after hot pressing to form a film.

In an embodiment of the present invention, hot pressing is performed at a temperature of 120 to 200 ° C in the second process, and cold pressing is performed at a temperature of 10 to 120 ° C.

Further, in the embodiment of the present invention, in the first process, the substrate layer material and the intermediate layer material are rolled and prepared, and the cork layer material is prepared as a sheet type.

Further, the present invention is a coating film comprising a base layer, a film layer laminated on the base layer and formed of a decoration film, and a coating layer laminated on the top of the film layer,

Wherein the decoration film comprises a base layer, an intermediate layer laminated on the base layer, and a cork layer laminated on the intermediate layer,

Wherein the intermediate layer comprises a lower adhesive layer, a nonwoven fabric layer laminated on the lower adhesive layer, and an upper adhesive layer laminated on the nonwoven fabric layer.

According to the present invention, the following advantages can be obtained.

1. Decoration film that can be used in automobile interior materials can be manufactured at low cost, so that it can be applied to general medium-sized vehicles as well as high-grade cars.

2. By introducing cork pattern, it is possible to improve visual quality, and as an open skin type, to give wood texture to the surface, it is possible to improve the merchantability.

3. It is environment-friendly because it uses cork bark without cutting the tree separately.

1 is a view showing a cross-sectional structure of a decoration film according to the present invention;
2 is a view showing a lamination process of a decoration film according to the present invention
3 is a view showing a cross-sectional structure of a molded part using a decoration film according to the present invention;
4 is a view showing a manufacturing process of a molded part according to the present invention;
5 is a cross-sectional view of a conventional molded part

Hereinafter, the present invention will be described with reference to the accompanying drawings.

As it is known, the cork tree has been cultivated for 70 years and it is used not only for cutting but also for environmentally friendly use.

Cork wood has excellent properties in insulation, sound insulation, electrical insulation, elasticity, etc., as well as a high quality unique to natural materials. It has VOC (volatile organic compound) removal, far infrared ray emission, deodorization and antibacterial functions.

The present invention relates to a decorating film using the cork wood as a material and a manufacturing method thereof, and more particularly, to an economical technology that can simplify structure and manufacturing process compared with conventional real wood parts and secure cost competitiveness.

In the present invention, a cork wood skin layer, which is a soft component of natural cork wood, is used in the production of a decoration film, and in order to ensure surface properties such as discoloration, peeling, Coating material is used, thereby making it possible to produce an open skin-type molded part (for example, an automobile interior part or the like) that realizes realistic wooden feel on the surface.

Referring to FIG. 1, a decoration film 100 according to the present invention has a cross-sectional structure in which a substrate layer 110, an intermediate layer 120, and a cork layer 130 are laminated.

That is, the decoration film 100 is composed of the base layer 110 of the lowest layer, the intermediate layer 120 laminated on the base layer 110, and the cork layer 130 of the uppermost layer laminated on the intermediate layer 120.

The base layer 110 is formed to a thickness of 0.2 to 0.6 mm, the intermediate layer 120 is formed to a thickness of 0.05 to 0.3 mm, and the cork layer 130 is formed to a thickness of 0.1 to 1.0 mm .

The cork layer 130 is formed of a cork wood skin layer, which is a soft component of cork wood, and is manufactured in the form of a laminated wood in which a thin cork wood plate is laminated and bonded to a certain thickness.

At this time, the cork layer 130 may implement various cork patterns according to the lamination and slicing method of the cork wood material forming the cork layer 130.

Since the natural cork material is not an artificial material, holes (pores, wood scratches, etc.) are present on the surface thereof. When vacuum molding of the decoration film 100 for manufacturing a molded part, the film 100 is partially stretched, Or may occur newly, so that the base layer 110 may be visibly exposed to the naked eye. In this case, the surface quality of the film 100 may deteriorate.

A nonwoven fabric is used for the intermediate layer 120 to improve the appearance difference and the sense of heterogeneity between the cork layer 130 and the base layer 110.

In the case of a single-fiber nonwoven fabric, it is preferable that a long-fiber nonwoven fabric having a density of 10 g / m 2 to 100 g / m 2 is used for the intermediate layer 120 because separation of the decoration film 100 is likely to occur at the interlayer interface.

Since the long fibers nonwoven fabric is a spunbond type and the fiber is not broken during the process of injecting (or spinning) the fibers, the tensile strength of the nonwoven fabric is increased compared to the nonwoven fabric, so that the interlayer peeling does not occur.

As the nonwoven fabric of the intermediate layer 120, it is more preferable to use a nonwoven fabric colored in a beige color for color matching with the cork of the cork layer 130.

That is, as the nonwoven fabric of the intermediate layer 120, it is preferable to use a long fiber nonwoven fabric colored in a beige color.

1, the intermediate layer 120 is formed by laminating adhesive layers 121 and 123 on upper and lower sides of the nonwoven fabric layer 122, respectively.

That is, the intermediate layer 120 includes a lower adhesive layer 121, a nonwoven fabric layer 122 laminated on the lower adhesive layer 121, and an upper adhesive layer 123 laminated on the nonwoven fabric layer 122.

The upper and lower adhesive layers 123 and 121 are used for adhesion between the cork layer 130 and the nonwoven fabric layer 122 and between the nonwoven fabric layer 122 and the base material layer 110. Examples of the adhesive layer material include urethane, Based, amide-based, and TPU (thermoplastic polyurethane), EVA (ethylene vinyl acetate), and the like.

For example, an amide-based hot melt adhesive or the like can be used as the amide-based adhesive.

As the adhesive layer material, a material having a melting temperature of 80 to 200 ° C can be used. When an adhesive layer material having a melting temperature of 200 ° C or more is used, the cork may be carbonized during lamination.

In other words, a material having a melting temperature of 80 to 200 ° C can be used as the adhesive layer material. Among them, urethane, acrylic, ester, amide, TPU (thermoplastic polyurethane) and EVA (ethylene vinyl acetate) desirable.

In particular, the upper adhesive layer 123 used for bonding between the cork layer 130 and the nonwoven fabric layer 122 is preferably made of a hot-melt (hot-melt web) material in the form of a nonwoven fabric.

When a general hot melt adhesive or an adhesive material (sheet or liquid adhesive material) is used as the material of the upper adhesive layer, the surface of the cork layer 130 is polished to cause a deterioration in surface quality.

In the case of a decoration film used for automobile interior parts, it is preferable to use a non-yellowing adhesive layer having a heat resistance temperature of 120 캜 or more as the upper adhesive layer in consideration of heat / light resistance conditions.

The base layer 110 is a layer which comes into contact with the injection material during the manufacture of the molded part using the decoration film 100. The base layer 110 is made of acrylonitrile-butadiene-styrene (ABS), polycarbonate (PC) ), Synthetic resin such as PET (polyethylene terephthalate), PP (polypropylene), PC (polycarbonate) and PMMA (polymethyl methacrylate) Or using a similar system is advantageous for adhesion with the substrate layer 110. [

At this time, the ABS material is most commonly usable as a substrate layer material.

The substrate layer 110 is preferably subjected to coloring for color matching with the cork layer 130, for example coloring using a beige color.

The decoration film 100 constructed as described above can be manufactured through a film lamination process of a belt roll type as shown in FIG. 2, that is, a belt roll lamination process.

First, to manufacture the decoration film 100, a substrate layer material for forming the base layer 110 of the film 100 and an intermediate layer material for forming the intermediate layer 120 are rolled and prepared, The cork layer material to form the layer 130 is prepared in a sheet type having a predetermined size and thickness.

The belt roll lamination process is suitable for joining and bonding two types of materials (roll type and sheet type) as described above, and it is possible to continuously and mass-produce the decoration film 100 as a roll type film.

That is, it is advantageous that the decoration film 100 is manufactured using a belt roll type lamination process which can be continuously produced in consideration of mass production.

For example, in the intermediate layer material, the materials of the upper adhesive layer 123, the nonwoven fabric layer 122, and the lower adhesive layer 121 constituting the intermediate layer 120 are preliminarily laminated prior to the lamination process, Roll type rolls may be used for the lamination process or the upper adhesive layer 123, the nonwoven fabric layer 122 and the lower adhesive layer 121 may be separately rolled and used in the lamination process have. Alternatively, the cork layer 130, the upper adhesive layer 123, and the nonwoven fabric layer 122 may be preliminarily laminated prior to the lamination process, rolled up in a laminated state in a total three-layer structure, and used in the lamination process.

It is also possible to prepare not only the cork layer material but also the base layer material and the intermediate layer material in a sheet type, not a roll type, and to produce a film through a belt roll lamination process.

During the belt roll lamination process, the respective materials are supplied simultaneously to the mixer 1 and are mixed while passing through the mixer 1. At this time, at the front end of the mixer 1, hot compression is performed, And cold pressing is performed at the rear end.

That is, in the belt roll lamination process, the film material is first bonded by hot pressing at the time of lamination through the assembling machine 1, followed by cold pressing immediately (continuously).

By such a process, it is possible to prevent and minimize distortion and deformation of the substrate layer material, and also to prevent post-distortion (warping, warping, etc.) caused by the cork layer material.

In order to optimize the lamination process, the lamination process between the substrate layer material and the intermediate layer material and the cork layer material is performed at a temperature not lower than the melting temperature of the adhesive material (80 to 200 ° C) It is preferable to perform compression at a temperature of 120 to 200 DEG C in hot pressing in consideration of the melting temperature of the adhesive material (adhesive layer material) used and the temperature range (temperature range) for preventing carbonization of the cork layer material.

The hot pressing during the lamination process is performed at a relatively high temperature as compared with the cold pressing. Specifically, the hot pressing is performed at a temperature of 120 to 200 ° C, and the cold pressing is performed at a temperature of 10 to 120 ° C.

A molded part 200 that can be used for automobile interior materials can be manufactured by using the decoration film 100 manufactured through the lamination process.

3, the molded part 200 may have a three-layer structure including a decoration film 100, specifically, a base layer 210 formed of an injection material, and a base layer 210, And a coating layer 220 formed on the top of the film layer 100 to be laminated.

At this time, the base layer 210 has a thickness of approximately 2.5 mm.

Fig. 4 schematically shows a process of forming and manufacturing the molded part 200. As shown in Fig.

4, the molded part 200 is formed into a predetermined shape through a film preheating process, a vacuum forming process, and a trimming process, and then a base layer 210 (see FIG. 4) is formed under the film layer 100 through an insert injection molding process. ).

The film preheating process is a process of preheating the decorating film 100 by preheating before vacuum molding.

The decorating film is heated at a temperature lower than or equal to the melting temperature of the adhesive material of the film intermediate layer 120 for 5 seconds to 90 seconds at the time of preheating, and then vacuum molding is performed.

If the film is heated to less than 5 seconds during film preheating, film forming and surface cracking may occur in the vacuum forming process, and deflection, deformation, and delamination may occur during heating over 90 seconds.

The vacuum forming step is a step of forming the film layer 100 by molding the preheated decoration film in a desired shape under vacuum conditions.

As another embodiment, it is also possible to apply a press forming process instead of the vacuum forming process.

The trimming process is a process of trimming the edge of the film layer 100 formed through vacuum forming and shaping the edge of the film layer 100 into a predetermined shape.

The insert injection molding process is a process of inserting a trimmed film layer 100 into a mold and injecting an injection material into the mold to mold the base layer 210.

The film preheating process, the vacuum forming process, the trimming process, the film inserting process, and the injection molding process are well known in the art, so a detailed description thereof will be omitted.

The base layer 210 is formed on the lower side of the film layer 100 formed in a predetermined shape and the coating layer 220 is formed on the upper side of the film layer 100.

An open skin type in which color stain painting and clear coating are performed on the upper part of the film layer 100 after the above-mentioned insert injection molding process to secure the surface durability of the molded part 200, Of real wood.

The process of coating the coating material on the film layer 100 to form the coating layer 220 includes a step of coating with color stain → drying → clear coating → drying → surface sanding → clear coating → drying → finished product (coating layer) If necessary, a primer may be applied to improve adhesion between the color stain and the clear coating step.

When the coating layer 220 is formed, the clear coating is carried out twice and an acrylic urethane type coating is used.

When the clear coating is performed only once, the material of the cork layer of the film layer 100 absorbs the clear paint, and the coating layer 220 may not be formed or the surface performance may be deteriorated.

The color stain coating is a coating method using a color paint including a color pigment, and a colored coating film is formed upon coating to realize a color feeling in the natural color film layer 100. The clear coating is a coloring paint containing no color pigment A transparent coating film or a translucent coating film (glossy / semi-glossy / matte coating film) is formed during coating by using a clear paint, and the coating layer 220 is provided with light resistance, abrasion resistance, scratch resistance and chemical resistance, .

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the scope of the present invention is not limited to the disclosed exemplary embodiments. Modifications are also included in the scope of the present invention.

100: Decoration film (film layer)
110: substrate layer
120: middle layer
121: Lower adhesive layer
122: nonwoven fabric layer
123: upper adhesive layer
130: Cork layer
200: Molded parts
210: base layer
220: Coating layer

Claims (14)

A base layer laminated on the base layer, an intermediate layer laminated on the base layer, and an uppermost cork layer laminated on the intermediate layer,
Wherein the intermediate layer comprises a lower adhesive layer, a nonwoven fabric layer laminated on the upper adhesive layer, and an upper adhesive layer laminated on the nonwoven fabric layer.
The method according to claim 1,
Wherein the nonwoven fabric layer comprises a long fiber nonwoven fabric having a density of 10 g / m 2 to 100 g / m 2.
The method according to claim 1 or 2,
Wherein the nonwoven fabric layer is made of a nonwoven material colored with a color similar to or the same as that of the cork layer material.
The method according to claim 1,
Wherein the adhesive material for the upper and lower adhesive layers is a material having a melting temperature of 80 to 200 ° C.
The method according to claim 1 or 4,
As the adhesive material for the upper and lower adhesive layers, one selected from the group consisting of urethane, acrylic, ester, amide, TPU (thermoplastic polyurethane) and EVA (ethylene vinyl acetate) Decoration film using natural cork material as a feature.
The method according to claim 1,
As the material for the substrate layer, a mixture of ABS (acrylonitrile-butadiene-styrene), PC (polycarbonate) and ABS (acrylonitrile-butadiene-styrene), PET (polyethylene terephthalate) Or a polymethyl methacrylate (PMMA) is used as the decorating film of natural cork material.
The method according to claim 1,
Wherein the substrate layer is made of a material colored with a color similar to or the same as that of the cork layer material.
The method according to claim 1,
Wherein the cork layer is formed of a cork wood skin layer which is a soft component of cork wood.
The method according to claim 1,
Wherein the base layer is formed to a thickness of 0.2 to 0.6 mm, the intermediate layer is formed to a thickness of 0.05 to 0.3 mm, and the cork layer is formed to a thickness of 0.1 to 1.0 mm. .
A first step of preparing a substrate layer material, an intermediate layer material and a cork layer material;
A second step of laminating and co-extruding the above materials simultaneously, followed by cold pressing immediately after hot pressing to form a film;
≪ / RTI > wherein the decorating film has a thickness of less than about < RTI ID = 0.0 &
The method of claim 10,
Wherein the hot-pressing is performed at a temperature of 120 to 200 ° C in the second step.
The method of claim 10,
Wherein the cold pressing is performed at a temperature of 10 to 120 ° C in the second step.
The method of claim 10,
Wherein the base layer material and the intermediate layer material are rolled and prepared in the first step, and the cork layer material is prepared in a sheet form.
A base layer, a film layer laminated on the base layer and formed of a decoration film, and a coating layer laminated on the top of the film layer,
Wherein the decoration film comprises a base layer, an intermediate layer laminated on the base layer, and a cork layer laminated on the intermediate layer,
Wherein the intermediate layer comprises a lower adhesive layer, a nonwoven fabric layer laminated on the upper adhesive layer, and an upper adhesive layer laminated on the nonwoven fabric layer.

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